[dwestmodesto]

I have a 2004 Dodge Ram2500 quadcab longbed 4wd with a 5.9l cummins turbo diesel. Not exactly what most would think of as an "economy" vehicle. I inherited it from my dad, and it is a great truck, so I am keeping it. On the highway it does pretty good, getting between 21 and 23mpg. I read yesterday here about using coroplast to clean up the air profile of the front of vehicles. I stopped by a sign shop while out doing errands today. I asked if they had any coroplast scrap from mistakes or other projects. I told him about your site and people using it on cars. He went and looked in the dumpster and came back with a piece 14" x 8'. He gave it to me for free. I asked him the price if I wanted to buy whole sheets...he quoted $30/sheet. I brought it home, and used 2 pieces to close off the sides of the ram's grill. The grill opening is much wider than the radiator/intercooler/oilcooler/air conditioner condensor. It is now 1/2 the original size. Coroplast is held on inside the grill with nylon zip ties. While having the hood open, the area on both sides of the radiator were an aerodynamic disaster. I cut two more pieces and sealed the area from the inside of the headlights down to the bumper to the sides of the radiator. I plan on painting it black, and it should all disappear. There is a 3/4" gap around the bottom of the headlights that I will seal with flexible black vinyl. I will seal the areas between bumper and hood, and between the bottom of the bumper and the air dam later. I am planning on extending the stock airdam down 6", and then sealing up the front 2/3 of the bottom of the engine bay. I will post some pics up of the first steps later.
Thanks for all the info I have gathered.
Dave